High-efficiency brushless hollow-cup DC motor stator

Abstract

The utility model discloses a kind of efficient brushless hollow cup DC motor stator, including the stator core made of high saturation soft magnetic material, the middle part of the stator core is equipped with core inner hole, the inside of the core inner hole is equipped with cup type winding, and the inside of the core inner hole is attached with insulating film, the cup type winding is by several sheet hexagonal winding column and is rolled by coiling machine, the cup type winding is fixed on the inner wall of core inner hole by high temperature epoxy adhesive layer;The utility model not only guarantees the electrical insulation between stator core and winding cup, but also reduces the inconvenience caused by artificial paste insulating film, improves the quality reliability of stator, shortens manufacturing cycle, improves work efficiency;Relative to filling process, manufacturing cycle is shortened by 2 / 3.

Description

Technical Field

[0001] This utility model relates to the technical field of motor stators, specifically a high-efficiency brushless hollow cup DC motor stator. Background Technology

[0002] Compared to slotted motors under equivalent conditions, coreless motors have higher output power density, smaller electrical time constant, smaller size, lighter weight, smoother operation, and faster response speed, leading to their increasingly widespread application. As a type of coreless motor, the stator manufacturing process of brushless coreless motors is complex, involving numerous tooling molds and special processes, posing many difficulties and limitations for mass production. Currently, the basic process involves first coating and gluing stamped stator laminations to form a stator core; then, using specialized tooling, the core is wound into a hexagonal winding, followed by flattening, pressing, semi-curing, winding, and shaping processes to form a cup-shaped winding. Existing methods include adding a thin film of a certain insulation level between the stator core and the cup-shaped winding, and then bonding and fixing the cup-shaped winding and stator core using specialized tooling molds. However, the existing process is relatively cumbersome, involves numerous tooling molds, and results in irregular and disordered winding slots, directly affecting the electrical performance of the motor itself and hindering mass production. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this utility model provides a high-efficiency brushless hollow cup DC motor stator.

[0004] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0005] This utility model discloses a high-efficiency brushless hollow cup DC motor stator, comprising a stator core made of highly saturated soft magnetic material. The stator core has an inner hole in the middle, and a cup-shaped winding is provided inside the inner hole. An insulating film is attached to the inner hole. The cup-shaped winding is formed by rolling several sheet-like hexagonal windings together using a rolling machine. The cup-shaped winding is fixed to the inner wall of the inner hole of the core by a high-temperature epoxy adhesive layer.

[0006] As a preferred technical solution of this utility model, the sheet-like hexagonal winding is formed by winding with tooling and then semi-cured.

[0007] As a preferred technical solution of this utility model, the cup-shaped winding is made by arranging multiple semi-cured sheet-like hexagonal windings neatly, rolling them by a rolling machine, and then curing the appearance of the cup-shaped winding under the protection of the mandrel.

[0008] As a preferred embodiment of the present invention, the sheet-like hexagonal winding includes symmetrically arranged vertical winding segments, and an oblique end is provided between the ends of the two vertical winding segments. The sheet-like hexagonal winding achieves axial symmetry with the connection of the oblique end as the central axis.

[0009] As a preferred embodiment of this utility model, the vertical winding segments of the plate-shaped hexagonal windings within the cup-shaped winding are parallel and aligned.

[0010] In a preferred embodiment of this invention, the thickness of the insulating film is 0.2 mm.

[0011] The beneficial effects of this utility model are:

[0012] This high-efficiency brushless hollow cup DC motor uses a stator core made of highly saturated soft magnetic material to improve the magnetic saturation of the stator core, ensuring sufficient margin in the main performance indicators of the motor body. This provides a foundation for the subsequent performance indicators of the motor body prototype to meet the standards. Among them, the use of tooling to wind sheet-like hexagonal windings ensures that the effective section of the winding is long enough, thereby further guaranteeing the performance indicators of the motor body. The varnish coating treatment of the inner hole of the core and the adhesive coating of the stator not only ensure the electrical insulation between the stator core and the winding cup, but also reduce the inconvenience caused by manually applying the insulating film, improve the reliability of the stator quality, shorten the manufacturing cycle, and improve the efficiency. Compared with the potting process, the manufacturing cycle is shortened by 2 / 3. Attached Figure Description

[0013] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0014] Figure 1 This is a schematic diagram of the structure of a high-efficiency brushless hollow cup DC motor stator according to this utility model;

[0015] Figure 2 This is a schematic diagram of the stator core of a high-efficiency brushless hollow cup DC motor according to this utility model;

[0016] Figure 3 This is a schematic diagram of the structure of the plate-shaped hexagonal winding of the stator of a high-efficiency brushless hollow cup DC motor according to this utility model;

[0017] Figure 4 This is a schematic diagram of the cup-shaped winding structure of the stator of a high-efficiency brushless hollow cup DC motor according to this utility model;

[0018] Figure 5 This is a schematic diagram of the heat dissipation mechanism of a high-efficiency brushless hollow cup DC motor stator according to the present invention;

[0019] Figure 6 This is a schematic diagram of the heat dissipation sleeve of a high-efficiency brushless hollow cup DC motor stator according to the present invention;

[0020] Figure 7This is a schematic diagram of the connecting tube of a high-efficiency brushless hollow cup DC motor stator according to the present invention;

[0021] Figure 8 This is a schematic diagram of the structure of a cooling block for a high-efficiency brushless hollow cup DC motor stator according to this utility model;

[0022] Figure 9 This is a schematic diagram of the structure of a thermally conductive retainer for the stator of a high-efficiency brushless hollow cup DC motor according to this utility model.

[0023] In the diagram: 1. Stator core; 2. Core inner hole; 3. Cup-shaped winding; 4. Insulating film; 5. Sheet-shaped hexagonal winding; 6. High-temperature epoxy layer; 7. Heat dissipation mechanism; 8. Heat dissipation sleeve; 9. Mounting hole; 10. Rubber sealing ring; 11. Sealing ring groove; 12. Paraffin heat-absorbing layer; 13. Thermally conductive retainer; 14. Graphene layer; 15. Cooling chamber; 16. Liquid inlet pipe; 17. Liquid outlet pipe; 18. Cooling block; 19. Semiconductor cooling chip; 20. Liquid channel; 21. Temperature sensor; 22. Connecting pipe; 23. Piston block; 24. Sealing layer; 25. End cap; 26. Vent hole; 27. Annular groove. Detailed Implementation

[0024] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0025] Example: Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, this utility model discloses a high-efficiency brushless hollow cup DC motor stator, comprising a stator core 1 made of high-saturation soft magnetic material. The stator core 1 has an inner core hole 2 in the middle. A cup-shaped winding 3 is provided inside the inner core hole 2, and an insulating film 4 is attached to the inside of the inner core hole 2. The cup-shaped winding 3 is formed by rolling several hexagonal sheet windings 5 ​​in rows by a rolling machine. The cup-shaped winding 3 is fixed to the inner wall of the inner core hole 2 by a high-temperature epoxy adhesive layer 6. The stator core is made of highly saturated soft magnetic material to improve its magnetic flux density saturation, ensuring sufficient margin for the main performance indicators of the motor body and providing a foundation for the subsequent performance indicators of the motor body prototype to meet the standards. Specifically, the use of tooling to wind sheet-like hexagonal windings ensures that the effective winding section is long enough, further guaranteeing the performance indicators of the motor body. The varnish coating treatment of the core inner hole and the stator adhesive coating not only ensure the electrical insulation between the stator core and the winding cups but also reduce the inconvenience of manually applying insulating film, improving stator quality reliability, shortening the manufacturing cycle, and increasing efficiency. Compared with the potting process, the adhesive coating process reduces the manufacturing cycle by 2 / 3.

[0026] The sheet-like hexagonal winding 5 is formed by winding with tooling and then semi-cured. The sheet-like hexagonal winding 5 ensures that the effective section of the winding is long enough and is semi-cured, which facilitates the subsequent neat arrangement of multiple semi-cured sheet-like hexagonal windings 5, which are then rolled into a cup-shaped winding 3 by a rolling machine.

[0027] The cup-shaped winding 3 is formed by arranging multiple semi-cured sheet-like hexagonal windings 5 ​​neatly and rolling them by a rolling machine. Under the protection of the mandrel, the cup-shaped winding 3 is surface-cured, which facilitates the shaping of the cup-shaped winding 3.

[0028] The hexagonal plate winding 5 includes symmetrically arranged vertical winding segments 501, and an inclined end 502 is provided between the ends of the two vertical winding segments 501. The hexagonal plate winding 5 achieves axial symmetry with the connection of the inclined end as the central axis. This symmetrical distribution, along with a sufficiently long effective winding section, provides a certain foundation for the subsequent performance indicators of the motor body prototype to meet the standards.

[0029] The vertical winding segments of the hexagonal sheet winding 5 within the cup-shaped winding 3 are parallel and aligned. The thickness of the insulating film 4 is 0.2 mm.

[0030] like Figures 5-9 As shown, a heat dissipation mechanism 7 is provided on the outer wall of the stator core 1. The heat dissipation mechanism 7 includes a heat dissipation sleeve 8 that is fitted around the stator core 1. The heat dissipation sleeve 8 is provided with a mounting hole 9 for the stator core 1 to be inserted. The upper and lower ends of the mounting hole 9 are provided with rubber sealing rings 10 for sealing the connection between the stator core 1 and the heat dissipation sleeve 8. The upper and lower ends of the mounting hole 9 are provided with sealing ring grooves 11 for installing the rubber sealing rings 10. By fitting the heat dissipation sleeve 8 around the stator core 1, the heat dissipation sleeve is used to dissipate heat from the stator, thereby preventing heat accumulation in the cup-shaped winding 3 during operation.

[0031] The mounting hole 9 has an inwardly recessed annular groove 27 surrounding its periphery. The annular groove 27 forms a sealed cavity with the outer wall of the stator core 1. The upper and lower ends of the mounting hole are sealed by a rubber sealing ring 10, thus providing good sealing performance. In addition, a paraffin heat-absorbing layer 12 is injected into the sealed cavity. The paraffin heat-absorbing layer 12 is mixed with thermally conductive filler graphene and metal particles. The phase change property of paraffin is used to absorb heat, thereby achieving heat dissipation for the stator and preventing heat accumulation in the cup-shaped winding 3 during operation.

[0032] The heat dissipation sleeve 8 is provided with multiple connecting pipes 22 communicating with the sealing ring groove 11. A piston block 23, which moves along the connecting pipe 22, is provided inside each connecting pipe 22. A sealing layer is provided between the piston block 23 and the connecting pipe 22. An end cap 25 is provided at the end of each connecting pipe 22, and a return spring 24 is provided between the end cap 25 and the piston block 23. The end cap 25 is provided with a vent hole 26 and is threadedly connected to the connecting pipe 22. This allows for adjustment of the capacity of the sealing cavity. When the paraffin heat-absorbing layer melts, the volume changes, causing the heat dissipation sleeve to expand. The piston block 23 can then move along the inner cavity of the connecting pipe, automatically adjusting the capacity of the sealing cavity.

[0033] A thermally conductive retainer 13 is fixed on the stator core 1 for contacting the inner side of the cup-shaped winding 3. The thermally conductive retainer 13 is in close contact with the side wall of the cup-shaped winding 3. This serves to install the cup-shaped winding 3 and prevent the hexagonal plate winding from warping during use, which could cause it to collide with the rotor and damage the warped edge, thereby damaging the cup-shaped winding 3 and causing the motor stator to be scrapped. The thermally conductive retainer 13 is connected to the heat dissipation sleeve 8 via a thermally conductive frame, and the surface of the thermally conductive retainer 13 is provided with a graphene layer 14. Utilizing the good thermal conductivity of the graphene layer, heat is transferred away and onto the heat dissipation sleeve, resulting in good heat dissipation. The heat dissipation sleeve 8 has a cooling chamber 15 inside, and the cooling chamber 15 contains coolant. The heat dissipation sleeve 8 is provided with an inlet pipe 16 and an outlet pipe 17 communicating with the cooling chamber. It also includes a cooling block 18 fixed to the casing, and a semiconductor cooling chip 19 is attached to the cooling block 18. The cooling block 18 has a liquid channel 20 inside, and the inlet pipe 16 and outlet pipe 17 communicate with the cooling chamber. 7. A circulating liquid path is formed between the liquid guide pipe and the liquid channel 20, and a temperature sensor 21 for detecting the temperature of the stator core 1 is installed in the sealed cavity. The temperature sensor detects the temperature of the stator core, and when the temperature sensor detects that the temperature of the stator core reaches the set cooling value, it indicates that the temperature of the paraffin heat-absorbing layer is too high. At this time, the semiconductor cooling chip 19 cools the cooling chip, which in turn cools the coolant. The cooled coolant is then sent into the cooling cavity 15 to exchange heat and cool the paraffin heat-absorbing layer. This ensures that the paraffin heat-absorbing layer continues to absorb heat, thus ensuring a good heat dissipation effect for the entire stator.

[0034] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A high efficiency brushless hollow cup DC motor stator, characterized by: The stator core (1) is made of a high-saturation soft magnetic material. The stator core (1) has an inner hole (2) in the middle. A cup-shaped winding (3) is provided inside the inner hole (2). An insulating film (4) is attached to the inside of the inner hole (2). The cup-shaped winding (3) is formed by rolling several sheet-like hexagonal windings (5) by a rolling machine. The cup-shaped winding (3) is fixed to the inner wall of the inner hole (2) by a high-temperature epoxy adhesive layer (6).

2. A high efficiency brushless hollow cup DC motor stator as defined in claim 1, wherein, The sheet-like hexagonal winding (5) is formed by winding with tooling and then semi-cured.

3. A high efficiency brushless hollow cup DC motor stator as set forth in claim 2, wherein, The cup-shaped winding (3) is made by rolling multiple semi-cured sheet-like hexagonal windings (5) neatly arranged by a rolling machine, and the appearance of the cup-shaped winding (3) is cured under the protection of the mandrel.

4. A high efficiency brushless hollow cup DC motor stator as set forth in claim 3, characterized by The sheet-like hexagonal winding (5) includes symmetrically arranged vertical winding segments (501), and an oblique end (502) is provided between the ends of the two vertical winding segments (501). The sheet-like hexagonal winding (5) achieves axial symmetry with the connection of the oblique end as the central axis.

5. A high efficiency brushless hollow cup DC motor stator as set forth in claim 4, wherein, The vertical winding segments of the plate-shaped hexagonal winding (5) within the cup-shaped winding (3) are parallel and aligned.

6. A high efficiency brushless hollow cup DC motor stator as set forth in claim 1, wherein, The thickness of the insulating film (4) is 0.2 mm.

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